Waffled impingement effusion method

BACKGROUND OF THE INVENTION

The present invention generally relates to gas turbine engines and, more particularly, to cooled components, such as combustor liners.

Customers and regulation agencies are continually applying pressure on engine manufactures to achieve lower specific fuel consumptions (SFCs) and emissions. This in turn requires combustors to operate at hotter temperatures yet reduce the cooling air required to cool the walls. There are two highly effective methods of cooling combustor walls, effusion (known by other names such as multi-hole) and impingement.

Effusion cooling is provided by an array of small holes positioned in the combustor liner wall. A supply of cooling air is passed through the holes from the cooler surface of the combustor liner to the surface exposed to higher temperatures. The cooling air actively cools the wall by convection as it passes through the hole and film cooling after the cooling air is discharged.

The effusion holes are typically between about 0.010 and about 0.050 inches in diameter and angled so that the centerline of the hole forms a 15 to 30 degree angle with respect to the surface of the wall. This small angle increases the length of the hole through the wall thus increasing the surface area from which the cooling air can extract heat from the wall material. The small angle also allows the cooling air to enter the combustor nearly parallel to the wall surface so that a cooling film is generated on the inside of the combustor liner.

Impingement cooling is provided by an impingement plate positioned on the cooler side of the combustor wall. The impingement plate has an array of small holes there through and is spaced at a distance from the surface of the wall to provide a gap. A supply of cooling air is passed through the holes to impinge the surface of the wall and thereby extract heat from the wall material. The surface heat transfer patterns can be controlled by the configuration of the hole array to provide additional cooling to hot spots.

It is well know to the industry that combining the two methods (impingement-effusion) can provide significant improvements in cooling efficiency over either method alone. It has been reported that the heat/mass transfer rate for impingement-effusion cooling is approximately 45% to 55% higher than that for impingement cooling alone and about three to four times that for effusion cooling alone. Although the quantitative results may vary with experimental set-up and application, combined impingement-effusion cooling systems may be more efficient than either alone for some applications.

In U.S. Pat. No. 4,695,247, an impingement-effusion method is described. The disclosed combustor is a double wall construction that uses pin fins to provide spacing between the inner and outer walls. The inner wall is provided with effusion holes and the outer wall is provided with impingement holes. Because the inner wall is exposed to higher temperatures than the outer wall, the thermal growth difference between the two walls results in high thermal stresses and poor control of the impingement gap. The high thermal stresses reduce combustor life and the poor gap control reduces impingement cooling efficiency.

A method for reducing the thermal stresses is described in U.S. Pat. No. 6,237,344. The disclosed impingement baffle has integrally formed dimples. The thermal growth difference between the baffle and the hot wall is alleviated by allowing the gap to float. Unfortunately, this also results in gap variations. The impingement efficiency is very sensitive to the gap between the wall and the impingement plate, which is difficult to control because of the difference in radial thermal growth between the impingement plate and the wall. In smaller cavities such as vanes this gap difference is acceptable, but in large diameter combustor walls the gap variation is a significant sacrifice in cooling efficiency.

Many known impingement-effusion methods have included rigidly attaching two structural walls to one another. The rigidly attached hot and cold structural walls result in high thermal stresses and component life limitations. To avoid these stresses, other methods have included floating one of the walls. Floating one of the walls requires some type of seal and the cooling efficiency is very sensitive to leakage that is present in most seals.

A method that does not require floating a wall or rigidly attaching two structural walls is described In U.S. Pat. No. 5,216,886. This method attaches an array of walled liner cells to a liner support structure. Cooling air enters the cells through impingement holes in the liner support. The cooling air exits the cells through holes in the side wall portions, entering the gaps between the cells, or exits the cells through holes in the top portions of the liner cells. The cooling air then sets up a cooling air film across the top portion of the cells. Although this method may avoid the thermal stress and leakage problems mentioned above, it requires multiple walled liner cells, which increases the surface area exposed to the hot combustion gas flow. Additionally, each liner cell must have sharp edges to comply with the hot side flow path, complicating liner manufacturing. Moreover, because the cells expand axially and laterally into the gaps to alleviate the thermal stresses, variations in the momentum of the cooling air that passes through the gaps may result in cooling film disruptions for some applications. Further, a combustor liner comprising multiple liner cells may not be suitable for thermal barrier coating (TBC) applications. Conventional techniques for applying TBC, such as plasma spray, may result in TBC being deposited in the gaps between the liner cells, which in turn may disrupt the flow of cooling air or close the gap that is required for thermal expansion.

As can be seen, there is a need for a method of attaching an impingement plate directly to the combustor in such a manner that will result in acceptable stresses but will have no leakage. Further, there is a need for a method of cooling a combustor liner by impingement-effusion that allows for conventional TBC application. An impingement effusion method is needed wherein thermal stress is relieved without increasing the surface area that is exposed to the high temperature gas flow.

SUMMARY OF THE INVENTION

In one aspect of the present invention, an apparatus for a component comprises a waffled impingement plate having at least one baffle cell, the baffle cell having a top portion and at least three side portions in contact with the top portion such that a cell cavity is formed; and at least one impingement hole positioned in the waffled impingement plate, the impingement hole capable of providing a cooling flow to a cold backside surface of the component.

In another aspect of the present invention, an apparatus for cooling a component comprises a waffled impingement plate conforming to at least a portion of a cold backside surface of the component, the waffled impingement plate comprising at least one baffle cell having at least one impingement hole there through, the baffle cell forming a cell cavity.

In still another aspect of the present invention, an apparatus for a component comprises a waffled impingement plate having at least one cell cavity and having at least one impingement hole there through, the waffled impingement plate conforming to a cold backside surface of said component.

In yet another aspect of the present invention, an apparatus for a component comprises at least one waffled impingement plate comprising a plurality of baffle cells, at least one baffle cell having a top portion with an area of between about 0.04 inch²and about 9.0 inch²; and at least one impingement hole positioned in said top portion.

In another aspect of the present invention, an apparatus for a combustor liner comprises a waffled impingement plate having a plurality of baffle cells, at least one baffle cell having a top portion and six side portions connected to the top portion, the top portion having an area of less than about 9.0 inch²and a plurality of impingement holes there through, each side portion having an outer end capable of being rigidly attached to a cold backside surface of the combustor liner.

In a further aspect of the present invention, a method of cooling a component comprises the step of passing a cooling flow through at least one impingement hole of a waffled impingement plate, the waffled impingement plate rigidly attached to a cold backside surface of the component and comprising at least one baffle cell having a cell cavity, the step of passing such that the cooling flow enters the cell cavity, impinges on the cold backside surface and enters an effusion hole of the component.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a plan view of a waffled impingement plate according to one embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 2</figref> is a cross-sectional view along line II of <figref idref="DRAWINGS">FIG. 1</figref>;

<figref idref="DRAWINGS">FIG. 3</figref> is a plan view of a waffled impingement plate according to another embodiment of the present invention;

<figref idref="DRAWINGS">FIG. 4</figref> is a plan view of a waffled impingement plate according to a third embodiment of the present invention; and

<figref idref="DRAWINGS">FIG. 5</figref> is a flow chart of a method of waffled impingement effusion cooling for a component according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, the present invention generally provides waffled impingement effusion cooling for components, such as combustor liners, and methods of cooling the same. The waffled impingement effusion cooling according to the present invention may find beneficial use in many industries including aerospace, automotive, and electricity generation. The present invention may be beneficial in applications including turbine engine combustors for aircraft propulsion, ground transportation, power generation, and auxiliary power generation. This invention may be useful in any impingement-effusion cooled component application.

In one embodiment, the present invention provides a waffled impingement plate for a combustor liner. Unlike the prior art, the impingement plate may comprise a plurality of individual cells to relieve the thermal growth difference between the cold impingement plate and the hot combustor wall. The use of individual impingement plate cells may allow the impingement plate to be rigidly attached to the combustor liner thus eliminating the need for a seal and its inherent problems with leakage. Thermal barrier coating may easily be applied to the liner, unlike prior art methods comprising individual walled liner cells. Thermal stress may be relieved without increasing the surface area exposed to the hot combustion gas flow because the stress relieving cells may be positioned on the backside of the liner as opposed to the hot gas flow side. This is unlike the prior art that relieves thermal stress by placing stress relieving walled liner cells on the hot gas flow side.

A waffled impingement plate <b>20</b> is depicted in <figref idref="DRAWINGS">FIG. 1</figref>. The waffled impingement plate <b>20</b> may comprise metal sheet stock. The waffled impingement plate <b>20</b> may conform to the contour of at least a portion of the component. The waffled impingement plate <b>20</b> may comprise a plurality of baffle cells <b>23</b>. The shape of the baffle cells <b>23</b> may comprise any shape that allows the baffle cells <b>23</b> to be nested to cover at least a portion of the component without blocking the effusion holes of the component. As used herein, nested baffle cells may be baffled cells <b>23</b> positioned such that the sides of adjacent baffle cells <b>23</b> may be about parallel to one another, as depicted in <figref idref="DRAWINGS">FIGS. 1 and 3</figref>. In other words, nested baffle cells may be baffle cells <b>23</b> that “fit together”, similar to the gridlike indented pattern of a waffle. The shape of the baffle cell <b>23</b> may include square, diamond, hexagon, and others. For example, square shaped baffle cells <b>23</b> are depicted in <figref idref="DRAWINGS">FIG. 1</figref> and hexagon shaped baffle cells <b>23</b> are depicted in <figref idref="DRAWINGS">FIG. 3</figref>. A waffled impingement plate <b>20</b> may comprise baffle cells <b>23</b> comprising one or more than one shape. For example, a waffled impingement plate <b>20</b> may comprise hexagon shaped baffle cells <b>23</b> or both diamond and triangle shaped baffle cells <b>23</b>. The baffle cells <b>23</b> may be formed by known methods, such as stamping and hydroforming. The waffled impingement plate <b>20</b> may comprise at least one baffle cell <b>23</b>.

A baffle cell <b>23</b>, as better seen in <figref idref="DRAWINGS">FIG. 2</figref>, may comprise a top portion <b>25</b> and a plurality of side portions <b>26</b> in contact with the top portion <b>25</b>. The baffle cell <b>23</b> may comprise at least three side portions <b>26</b> such that a cell cavity <b>27</b>(impingement gap) is formed. A cell cavity <b>27</b> may be a recess defined by the top portion <b>25</b> and side portions <b>26</b> of the baffle cell <b>23</b>. The side portions <b>26</b> may be at an angle <b>28</b> of at least about 90° relative to the top portion <b>25</b>. For some applications, the side portions <b>26</b> may be slanted due to sheet metal stamping limitations and the baffle cell <b>23</b> may resemble a truncated pyramid. For example, the angle <b>28</b> may be about 95° relative to the top portion <b>25</b> such that the side portions <b>26</b> slant outward. The angle <b>28</b> may depend on factors including manufacturing limitations, sheet stock dimensions and sheet stock composition. For some applications, the area of the top portion <b>25</b> may be between about 0.04 inch²and about 9.0 inch². The dimensions of the baffle cell <b>23</b> may include any dimensions that are capable of relieving thermal stress between the waffled impingement plate <b>20</b> and the component.

The baffle cell <b>23</b> may have at least one impingement hole <b>24</b> there through such that a cooling flow <b>31</b> may enter the cell cavity <b>27</b> and impinge on a cold backside surface <b>22</b> of the component. <figref idref="DRAWINGS">FIG. 2</figref> depicts two baffle cells <b>23</b> in contact with the cold backside surface <b>22</b> of a portion of a combustor liner <b>21</b>. The cold backside surface <b>22</b> may be the surface of a component that is away from a hot gas flow <b>36</b>, such as combustion gases, and a hot side <b>35</b> may be the surface of a component that is exposed to the hot gas flow <b>36</b>.

The number of impingement holes <b>24</b> may vary. The number of impingement holes <b>24</b> may depend on factors including application, the shape of the baffle cell <b>23</b>, the diameter of the impingement hole <b>24</b>, and the area of the baffle cell <b>23</b>. For example, for a hexagon shaped baffle cell <b>23</b> for use in an annular combustor liner application, there may be about fourteen impingement holes <b>24</b>, each having a diameter of about 0.025 inches. For some applications, the impingement hole <b>24</b> may have a diameter between about 0.01 and about 0.05 inches. The diameter of the impingement hole <b>24</b> may vary and may depend on factors including the application, the number of impingement holes <b>24</b>, the shape of the baffle cell <b>23</b>, and the cavity height <b>29</b>. The cavity height <b>29</b> (impingement distance) may be the distance between an impingement hole <b>24</b> and a cold backside surface <b>22</b> of a component, such as combustor liner <b>21</b>. For some applications, the cavity height <b>29</b> may be about three times the diameter of the impingement hole <b>24</b>. For example, for a baffle cell <b>23</b> having a cavity height <b>29</b> of about 0.060 inches, the diameter of the impingement hole <b>24</b> may be about 0.020 inches. The impingement holes <b>24</b> may be formed by conventional drilling techniques, such as electrical-discharge machining (EDM) and laser machining.

The impingement holes <b>24</b> may be positioned and sized for optimal heat transfer with minimal cross flow degradation. Any known method of heat transfer analysis may be useful. Factors affecting impingement cooling effectiveness may include the rate of flow of the cooling flow <b>31</b>, cross flow degradation, impingement distance (cavity height <b>29</b>), and the diameter of the impingement holes <b>24</b>. Cross flow degradation may be due to the spent air interfering with the intended impingement surfaces while the spent air exits the cell cavity <b>27</b>. During operation, the cooling flow <b>31</b> may exit the cell cavity <b>27</b> through effusion holes <b>30</b> positioned in the component.

The component may have a plurality of effusion holes <b>30</b> there through. The effusion holes <b>30</b> may be formed by conventional drilling techniques such as electrical-discharge machining (EDM), stationary percussion laser machining and percussion on-the-fly laser drilling or with complex casting techniques. The effusion holes <b>30</b> may be angled with respect to the cold-backside surface <b>22</b> such that a cooling flow <b>31</b> through the effusion holes <b>30</b> may provide a cooling film <b>37</b> on the hot side <b>35</b>. For some applications, the effusion hole <b>30</b> and the cold backside surface <b>22</b> of the combustor liner <b>21</b> may form an angle (not shown) of between about 15° and about 30°. The diameter of an effusion hole <b>30</b> may vary with application and may depend on factors including the number and diameter of the impingement holes <b>24</b>. For some applications, the effusion hole <b>30</b> may have a diameter between about 0.01 and about 0.05 inches. The effusion hole <b>30</b> may comprise any known effusion hole shape, such as cylindrical and tapered. The number of effusion holes <b>30</b> may vary and may depend on factors including the diameter of the impingement holes <b>24</b>, the number of impingement holes <b>24</b>, the temperature of the hot gas flow <b>36</b>, and the dimensions and composition of the component. The density of the effusion holes <b>30</b> may vary with application and may depend on factors including the dimensions and composition of the component, the velocity of the cooling flow <b>31</b>, the temperature of the hot gas flow <b>36</b>, and the density of the impingement holes <b>24</b>. For example, a hexagon shaped baffle cell <b>23</b>, having a diameter of about 0.8 inch and nineteen impingement holes <b>24</b> there through, may be positioned over about twenty-two effusion holes <b>30</b>, as seen in <figref idref="DRAWINGS">FIG. 3</figref>. In <figref idref="DRAWINGS">FIGS. 3 and 4</figref>, the effusion holes <b>30</b> are depicted for placement purposes only. The effusion holes <b>30</b> are positioned in a component (not seen in these figures), not in the baffle cell <b>23</b> as these figures appear to suggest. <figref idref="DRAWINGS">FIG. 4</figref> also depicts a 0.8 inch diameter baffle cell <b>23</b>, but with fourteen impingement holes <b>24</b> and eighteen effusion holes <b>30</b>. For some combustor applications, the density of the effusion holes <b>30</b> may be between about 10 and about 100 holes/in².

The component, such as but not limited to combustor liner <b>21</b>, may comprise any component exposed to high temperatures. Useful components may include gas turbine engine components, for example combustors, vanes and shrouds. The component may comprise a metal or a metal alloy, such as HA230™ and HA188™ available from Haynes International. The component may comprise a component having a TBC (not shown) applied to the hot side <b>35</b>. For example, a TBC comprising Zircoat™ (available from PRAXAIR) may be deposited by plasma spray technique prior to effusion hole <b>30</b> formation. Any TBC composition, TBC application technique, and effusion hole formation technique may be useful with the present invention. The TBC may provide thermal insulation against the hot gas flow <b>36</b> and may reduce the cooling requirement of the component.

One or more than one waffled impingement plate <b>20</b> may be attached to the component. For example, for an application wherein the component has a cold back-side surface <b>22</b> of about 100 in²and the baffle cells <b>23</b> each have a top portion <b>25</b> of about 1.0 in², one waffled impingement plate <b>20</b> having about one hundred baffle cells <b>23</b> may be attached to the component. Alternatively, ten waffled impingement plates <b>20</b>, each having about ten baffle cells <b>23</b> may be attached to the component. For another alternative, about one hundred waffled impingement plates <b>20</b>, each having one baffle cell <b>23</b> may be attached to the component. The number of waffled impingement plates <b>20</b> may vary and may depend on manufacturing preference.

The waffled impingement plate <b>20</b> may be positioned on the cold backside surface <b>22</b> of a component such that a cooling flow <b>31</b> through an impingement hole <b>24</b> of the waffled impingement plate <b>20</b> is capable of impinging on the cold back-side surface <b>22</b> and entering an effusion hole <b>30</b> of the component. The waffled impingement plate <b>20</b> may be attached such that blockage of the effusion holes <b>30</b> is avoided. In other words, the waffled impingement plate <b>20</b> may be positioned such that it covers at least a portion of the component but does not block the effusion holes <b>30</b>.

The waffled impingement plate <b>20</b> may be rigidly attached to the cold backside surface <b>22</b> of the component. For example, the waffled impingement plate <b>20</b> may be held in place by tacking or spot-welding and then brazed, E-Beam welded or Laser welded to the cold back-side surface <b>22</b>. For some applications, at least one alloying hole <b>32</b> may be positioned in the waffled impingement plate <b>20</b>, as seen in <figref idref="DRAWINGS">FIGS. 1 and 3</figref>. Alloying holes <b>32</b> are known in the art and may facilitate brazing. Alloying holes <b>32</b> may allow braze material (not shown) to be wicked onto the contact areas <b>33</b>. The contact areas <b>33</b>, depicted in <figref idref="DRAWINGS">FIG. 2</figref>, may be the portions of the waffled impingement plate <b>20</b> that are in contact with the cold backside surface <b>22</b>. A contact area <b>33</b> may comprise an outer end <b>34</b> of a side portion <b>26</b> of a baffle cell <b>23</b>. The outer end <b>34</b> may be the end of a side portion <b>26</b> that is furthest from the top portion <b>25</b>. The waffle impingement plate <b>20</b> may be attached to the component by brazing the contact areas <b>33</b>. The waffle impingement plate <b>20</b> may be attached to the component by welding the contact areas <b>33</b>.

A method <b>40</b> of waffled impingement effusion cooling for a component is depicted in <figref idref="DRAWINGS">FIG. 5</figref>. The method <b>40</b> may comprise a step <b>41</b> of passing a cooling flow <b>31</b> through at least one impingement hole <b>24</b> of a waffled impingement plate <b>20</b>. The cooling flow <b>31</b> may be passed such that the cooling flow <b>33</b> enters a cell cavity <b>27</b> and impinges on a cold backside surface <b>22</b> of the component. The impingement hole <b>24</b> may be in flow communication with at least one effusion hole <b>30</b> of the component. The cooling flow <b>33</b> may exit the cell cavity <b>27</b> through the effusion hole(s) <b>30</b> of the component. The cooling flow <b>33</b> may exit the cell cavity <b>27</b>, providing convective cooling inside the effusion hole <b>30</b> and a cooling film <b>37</b> on the hot side <b>35</b> of the component.

As can be appreciated by those skilled in the art, the present invention provides improved impingement effusion methods. Seals and their inherent leakage problems are eliminated by rigidly attaching the impingement plate to the component. Thermal stress is alleviated by the small sized baffle cells of the impingement plate.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.